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Competent solutions for nuclear power plants – from flexible upgrading of existing plants to the innovative largest nuclear unit in the worldDr. Andreas Wichtmann, Siemens Power Generation

June 2-4, 2006Power Generation 2Dr. Wichtmann

Overview

Nuclear Service Engineering

Summary

Advanced Disk Design

Introduction

Engineering Analysis

Nuclear New Apparatus


Nuclear Steam Turbine References

Nuclear Steam Turbines built by Siemens Power Generation as

ParsonsWestinghouseSiemens KWU

First operation ~50 years agoMore than 130 UnitsMore than 120 GW total rating

Nuclear Steam Turbines built by Siemens Power Generation as

ParsonsWestinghouseSiemens KWU

First operation ~50 years agoMore than 130 UnitsMore than 120 GW total rating


0

200

400

600

800

1000

1200

1400

1600

1800

1950 1955 1960 1965 1970 1975 1980 1985 1990 1995 2000 2005 2010

Siemens KWUParsonsWestinghouseMods&UpgradesOlkiluoto 3

Nuclear Steam Turbines References

Isar 2

MWel

Year of commission

Olkiluoto 3


Overview

Summary


Introduction





NPP Yonggwang, South Korea

Yonggwang Nuclear Units 1 & 2

Westinghouse OEM design

997 MWe nominal rating

PWR / Moisture Separator Reheater


Initiate Order

Assign Engineers and

Divide-upWork Scope

Notify Customer of Analysis

Findings / Impacts as They Occur

Perform Analyses

Customer Comments

andReview

Final (HBD or Mech.)

ReportIssuance

FinalizeParameters

Engineering Analysis Process


Yonggwang thermal uprate evaluation

Thermodynamic Modelling at

Three phase evaluation:

Feasibility Evaluations of the Existing TG Components

Further System Evaluations and Recommendations

current operation parameters (HBD).uprate power level and Valves Wide opencustomer power levels (i.e. 100%, 75%, etc.)


Partial Arc Impulse

Partial Arc Reaction

Full Arc Reaction with Blade Rings

Full Arc Reaction with Inner Cylinder

1st Stage Type Impulse Reaction Reaction Diagonal Reaction

Outer Cylinder Pressure

Base high highest low

Blade Path Effectiveness 0 + ++ +++ Costs 0 - - - Scope Rotor*,

Blade Rings (4), Nozzle Block

Rotor, Blade Rings (4), Reaction Nozzle Block

Rotor, Blade Rings (4) Flow Guides,

Rotor, Blade Rings (2) Inner Cylinder,

HP Upgrade Comparison

* reuse possible


Monoblock rotor

3D blading

Diagonal inlet stage

10-year inspection

Inner casing replaces control stage and both #1 blade rings

Option for stainless steel inner casing and blade carriers

HP Turbine (Full-Arc) Design Features


Overview

Summary

Introduction






2 LP Turbine Upgrades, Westinghouse BB381

Customer ContractUpgrade of 2 LP Turbines with Rotors and stationary blade path, incl. Installation in Spring 2006

Main Success:• Expected performance increase of

21 MW from technology only, with potential for future reactor uprate

• Cure from generic SCC problems

Status• Notice of Award received 2004-01-09

NPP Kuosheng, Taiwan


NPP KuoshengLP Turbine, Shrunk-on Disk Design

13.9 m2 nuclear LP turbine


Avoidance of Stress Corrosion Cracking

Engineering

Shot Peening

ManufacturingHeat TreatmentMaterial Know How

Quality Assurance

1400

Tim

e to

Cra

ck In

itiat

ion

[h]

Stress Corrosion Cracking due to Hydrogen Embrittlement

0.2% Yield Strength [MPa]600 800 1000

104

103

105

No Crack Initiation

1200

0.2%-Yield Strength [MPa]

Cra

ck G

row

th R

ate

[m/s

]

10-12

10-11

10-10

10-9

10-8

10-7

600 800 1000 1200

HydrogenInduced SCC

1400

Compressive Stress Area

Shoot peening

Rolling of shaft

US inspection


Shrunk-on Disc Design Success against SCC

in operation more than 2.750.000 hours total= more than 40 million disk operating hours

in operation for up to 225.000 hours

more than 660 examinations on Disks

No replacement of rotors or disks due to stress corrosion cracks, as performed by most competitors


Original Equipment Data

Plant OEM Country CapacityMW

RetrofitDate

RetrofitComponent

Grafenrheinfeld Siemens KWU Germany 1300 1993 HP, LPKRB II Block B Siemens KWU Germany 1310 1993 HP, LPKRB II Block C Siemens KWU Germany 1310 1994 HP, LPGrohnde Siemens KWU Germany 1393 1995 LPPhilippsburg 1 Siemens KWU Germany 901 1995 LPPhilippsburg 2 Siemens KWU Germany 1343 1995 LPUnterweser Siemens KWU Germany 1300 1995 HP, LPAlmaraz 2 Westinghouse Spain 950 1996 HP, LPAsco 2 Westinghouse Spain 930 1996 HP, LPBrokdorf Siemens KWU Germany 1367 1996 LPIsar 2 Siemens KWU Germany 1369 1996 LPAlmaraz 1 Westinghouse Spain 950 1997 HP, LPAsco 1 Westinghouse Spain 930 1997 HP, LPEmsland Siemens KWU Germany 1314 1998/2001 LPIsar 1 Siemens KWU Germany 905 1998 LPForsmark 3 ABB Sweden 1155 2004 LPNeckarwestheim II/3 DS Siemens KWU Germany 1314 2004 LPKrümmel Siemens KWU Germany 1316 2006 LP

Retrofit Data

Nuclear Steam Turbine ReferencesRetrofit/Upgrades for half speed 50 Hz

Siemens recommends for its turbines with disc type rotors a main inspection only after 100.000 h which is accepted by the German authority (VGB)


Steam Turbine Retrofit/Upgrades ReferencesNon OEM products 50 Hz/60 Hz

Original Equipment Data Retrofit Data


RetrofitDate

RetrofitComponent

Connecticut Yankee Westinghouse USA 648 1987 LPAlmaraz 2 Westinghouse Spain 950 1996 HP, LPAlmaraz 1 Westinghouse Spain 950 1997 HP, LPLimerick 1 GE USA 1138 1998 HP, LPLimerick 2 GE USA 1138 1999 HP, LPComanche Peak 1 Siemens USA 1215 2002 LPSusquehanna 2 GE USA 1168 2003 HP, LPSalem 2 Westinghouse USA 1170 2003 HPSalem 1 Westinghouse USA 1170 2004 HP, LPForsmark 3 ABB Sweden 1155 2004 LPSusquehanna 1 GE USA 1128 2004 HP, LPComanche Peak 2 Siemens USA 1128 2004 LPCooper Westinghouse USA 801 2005 LPSendai MHI Japan 900 2006/2005 HP, LPKuosheng Westinghouse Taiwan 1000 2006 LPSouth Texas Project Westinghouse USA 1300 2006-2007 LPDC Cook GE USA 1134 2006 LPSouth Texas 1 Westinghouse USA 1350 2006 LPSouth Texas 2 Westinghouse USA 1350 2007 LPGinna Westinghouse USA 528 2006 HP

Original Equipment Data Retrofit Data


RetrofitDate

RetrofitComponent

Connecticut Yankee Westinghouse USA 648 1987 LPAlmaraz 2 Westinghouse Spain 950 1996 HP, LPAlmaraz 1 Westinghouse Spain 950 1997 HP, LPLimerick 1 GE USA 1138 1998 HP, LPLimerick 2 GE USA 1138 1999 HP, LPComanche Peak 1 Siemens USA 1215 2002 LPSusquehanna 2 GE USA 1168 2003 HP, LPSalem 2 Westinghouse USA 1170 2003 HPSalem 1 Westinghouse USA 1170 2004 HP, LPForsmark 3 ABB Sweden 1155 2004 LPSusquehanna 1 GE USA 1128 2004 HP, LPComanche Peak 2 Siemens USA 1128 2004 LPCooper Westinghouse USA 801 2005 LPSendai MHI Japan 900 2006/2005 HP, LPKuosheng Westinghouse Taiwan 1000 2006 LPSouth Texas Project Westinghouse USA 1300 2006-2007 LPDC Cook GE USA 1134 2006 LPSouth Texas 1 Westinghouse USA 1350 2006 LPSouth Texas 2 Westinghouse USA 1350 2007 LPGinna Westinghouse USA 528 2006 HP

For US-power plant „Limerick“ Siemens got the permission by the US-Nuclear Regulatory Commission (NRC) to extend the inspection intervals from 6 to 10 years


Overview


Summary

Introduction





Finnish New Nuclear Power Plant Olkiluoto 3 - Basic Data

Location Olkiluoto, FinlandReactor Supplier Framatome ANP Reactor Type Pressurized Water

Reactor, EPR

Turbine Supplier Siemens AG, Power Generation

Net Output ~1600MWNet Efficiency >37%Com. Operation 2009

Location Olkiluoto, FinlandReactor Supplier Framatome ANP Reactor Type Pressurized Water

Reactor, EPR

Turbine Supplier Siemens AG, Power Generation

Net Output ~1600MWNet Efficiency >37%Com. Operation 2009


NPP Productline

Double bearing (half speed) ; fixed bearing arrangement

High-performance LP blading for different

up to 30qm

Efficient erosionprotection measures

Fully 3-dimensional high

performance variable reaction blading (3DVTM)

Fabricated welded design

Evolution ofKONVOI turbosetfor 1000MW to 1700M application

vertical arrangement2-stage heater only 2 inlets top/bottom

2 outlets in lower part


LP Turbine World largest steel blade

Hub Diameter Di ~3060 mmTip Diameter Da ~6720 mmBlade Length L ~1830 mmBlade Weight (incl. Root) ~340 kgCentrifugal Force of one LSB 12 MN

Di

L Da


PerformanceEfficiency Increase from Isar II to OL3

LP TurbineUpgrade

HP TurbineUpgrade

IncreasedMain Steam

Pressure

ImprovedWater Steam

Cycle

30 sqm LSBImproved

Backpressure25 mbar

Main SteamPressure

65 to 78 bar

2 stage MSR7 feed water

reheater

~36%

34%

35%

36%

37%

38%

39%

40%

Isar II OL 3

~40 %


Summary

Design features of conventional fleet are implemented

Service solution by profound engineering studies

Advanced disk design to avoid SCC

Efficiency increase by innovative bladingdesign

Design is based on proven nucleartechnology (>40 years)

Innovative nuclear turboset design forgross power output of ~1715MW at 40% gross efficiency